Solar powered pressurized electronics enclosure for pumping units

Abstract

The present disclosure is directed to an electronic monitoring system having various sensors for monitoring a pumping unit and/or well head. In an embodiment, the system includes a load cell and position sensor that generate dynamometer information. The monitoring system is suited for remote well applications as the system is self-powered (e.g., solar powered) and has wireless communication capabilities allowing remote monitoring in substantially real-time.

What is claimed is: 
     
       1. A monitoring system for use with an oil and gas well head, comprising:
 a load sensor assembly that generates a load output indicative of a force between a carrier bar and a polished rod clamp of a well; 
 a distance sensor that generates a position output indicative of a location of the load sensor assembly relative to the well head; 
 a magnetometer; 
 a pressure-tight housing removably coupled to the load sensor assembly, the pressure-tight housing including within its interior:
 a processor operatively connected to the load sensor assembly, the distance sensor and the magnetometer, wherein the processor utilizes the position output of the distance sensor to calibrate the magnetometer and wherein, upon calibrating the magnetometer, the processor deactivates the distance sensor, wherein a magnetic output of the magnetometer provides the position output; 
 a wireless communications device for wirelessly transmitting data associated with load outputs of the load sensor assembly and position outputs of the distance sensor or magnetometer; and 
 a battery that supplies power to the processor and the wireless communications device; and 
 
 a solar panel connected to the pressure-tight housing and configured to provide power to the battery. 
 
     
     
       2. The monitoring system of  claim 1 , wherein the load sensor assembly comprises:
 a support basket having a first portion configured for removable coupling to the pressure-tight housing; and 
 at least a first load cell supported by a second portion of the support basket for measuring forces between said polished rod clamp and said carrier bar. 
 
     
     
       3. The monitoring system of  claim 2 , wherein the support basket comprises a receiving channel sized to receive and partially surround a polished rod. 
     
     
       4. The monitoring system of  claim 3 , wherein the basket further comprises second and third load cells, wherein the first, second and third cells are equally spaced around the receiving channel of the support basket. 
     
     
       5. The monitoring system of  claim 1 , further comprising:
 a pressure sensor disposed the interior of the pressure-tight housing that generates a pressure output indicative of a pressure within the interior of the pressure-tight housing; 
 wherein the processor is configured to disconnect power upon the pressure within the interior of the pressure-tight housing falling below a predetermined pressure. 
 
     
     
       6. The monitoring system of  claim 5 , further comprising:
 at least one gas sensor disposed on an exterior surface of the pressure-tight housing and operatively connected to the processor. 
 
     
     
       7. The monitoring system of  claim 1 , wherein the solar panel is connected to the pressure-tight housing at an angle relative to a vertical axis of the pressure-tight housing. 
     
     
       8. The monitoring system of  claim 1 , wherein the pressure-tight housing further comprises at least one nozzle for pressurizing an interior of the pressure-tight housing. 
     
     
       9. The monitoring system of  claim 1 , wherein the distance sensor is attached to the housing. 
     
     
       10. The monitoring system of  claim 9 , wherein the distance sensor further comprises a gimbal attached to the housing, wherein the gimbal provides three axes of adjustment for the distance sensor. 
     
     
       11. The monitoring system of  claim 1 , wherein the distance sensor comprises a sonar sensor. 
     
     
       12. The monitoring system of  claim 1 , wherein the distance sensor comprises a Lidar sensor. 
     
     
       13. The monitoring system of  claim 12 , wherein the Lidar sensor is housed in an enclosure separate from the pressure-tight housing. 
     
     
       14. The monitoring system of  claim 13 , wherein the enclosure further comprises a sight window, wherein the Lidar emits and detects through the sight window. 
     
     
       15. The monitoring system of  claim 12 , wherein the Lidar sensor is disposed within the interior of the pressure-tight housing. 
     
     
       16. The monitoring system of  claim 15 , wherein the pressure-tight housing further comprises a sight window, wherein the Lidar sensor emits and detects through the sight window. 
     
     
       17. A monitoring system for use with an oil and gas well head, comprising:
 a load sensor assembly that generates a load output indicative of a force between a carrier bar and a polished rod clamp of a well; 
 a distance sensor that generates a position output indicative of a location of the load sensor relative to the well head; 
 a magnetometer; 
 a processor operatively connected to the load sensor assembly, the distance sensor and the magnetometer, wherein the processor utilizes the position output of the distance sensor to calibrate the magnetometer and wherein, upon calibrating the magnetometer, the processor deactivates the distance sensor, wherein a magnetic output of the magnetometer provides the position output; and 
 a wireless communications device for wirelessly transmitting data associated with load outputs of the load sensor assembly and position outputs of the distance sensor or magnetometer. 
 
     
     
       18. The monitoring system of  claim 17 , further comprising:
 a battery that supplies power to the processor and the wireless communications device; and 
 a solar panel configured to provide power to the battery. 
 
     
     
       19. The monitoring system of  claim 18 , further comprising:
 a pressure-tight housing removably coupled to the load sensor assembly, the pressure-tight housing including within its interior the processor, the wireless communications device and the battery. 
 
     
     
       20. The monitoring system of  claim 17 , wherein the distance sensor is one of a sonar sensor and a Lidar sensor.